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GENERAL INFORMATION 23B-0-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. SPECIFICATIONS 23B-1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSMISSION MODEL TABLE 23B-1-1. . . . . . . . . . . . . . . . . . . . . . . .GENERAL SPECIFICATIONS 23B-1-2. . . . . . . . . . . . . . . . . . . . . . . . . . .SERVICE SPECIFICATIONS 23B-1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .VALVE BODY SPRING IDENTIFICATION TABLE 23B-1-4. . . . . . . . .SNAP RING, SPACER AND THRUST WASHERFOR ADJUSTMENT 23B-1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TORQUE SPECIFICATIONS 23B-1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . .SEALANTS 23B-1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. SPECIAL TOOLS 23B-2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. TRANSMISSION 23B-3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. FORWARD CLUTCH AND INPUT SHAFT 23B-4-1. . . . . . . . . . . . . . . . . .5. REVERSE BRAKE 23B-5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. VALVE BODY 23B-6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. OUTPUT SHAFT 23B-7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8. DIFFERENTIAL 23B-8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23B-0-1

CONTINUOUSLYVARIABLE

TRANSMISSION(CVT)

CONTENTS

AddedPWEE9514-HNov. 2001Mitsubishi Motors Corporation

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23B-0-2

NOTES


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CVT (EW) General Information 23B-0-3

GENERAL INFORMATIONSECTIONAL VIEW


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CVT (E W) General Information23B-0-4

AddedPWEE9514-HMitsubishi Motors Corporation Nov. 2001

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CVT (E W) Specifications 23B-1-1

1. SPECIFICATIONSTRANSMISSION MODEL TABLEMODEL 2001

Transmission models Vehicle model Engine model

F1C1A-1-J4Z CS3A 4G18-SOHC

EXP F1C1A-1-J5Z CS2A 4G15-GDI

F1C1A-2-F2Z CS5A 4G93-GDI

MODEL 2002

Transmission models Vehicle model Engine model



F1C1A-1-J5Z CS2A 4G15-GDI

F1C1A-2-F2Z CS5A 4G93-GDI


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CVT (E W) Specifications23B-1-2

GENERAL SPECIFICATIONS

Item Specifications

Transmission model F1C1A-1 F1C1A-2

Type 3-element, 1-stage, 2-phase typeorque conver er

Lock-up Provided

Transmission type Steel-belt-driver, continuously variable automatic transmission

Forward gear ratios 2.316 0.445

Reverse gear ratio 2.588

Final reduction ratio 5.686 5.219

Number of forward clutch discs 2 3

Number of reverse brake discs 3 or 4 (J6Z) 4


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SERVICE SPECIFICATIONS

Item Standard value

Input shaft end play mm 0.30 0.60

Output shaft preload mm 0.045 0.105

Differential case end play mm 0.045 0.165

Forward clutch piston end play mm 1.2 1.4

Reverse brake piston end play mm 1.6 1.8


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VALVE BODY SPRING IDENTIFICATION TABLE

Spring Wirediameter

Outsidediameter

Insidediameter

Free length Numberof loops

Shift control valve spring 0.9 5.1 0.15 16.496 9

Reducing valve spring 1.4 6.8 0.15 33.882 13

Damper clutch control valve spring 0.6 5.2 0.15 26.521 16

One-way valve spring 0.6 4.5 0.1 13.46 13

Primary pressure relief valve spring 1.4 7.5 0.15 36.09 15

Exhaust valve spring 0.6 6.8 0.2 24.90 12

Torque converter pressure valve spring 1.4 8.0 0.15 53.50 17

Regulator valve spring 1.0 6.9 0.2 25.62 11

Clutch pressure reducing valve spring 1.2 6.0 0.15 24.95 11

Line pressure relief valve spring 1.2 7.5 0.15 40.71 13

Clutch pressure control valve spring 1.0 4.1 0.15 27.15 15


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SNAP RING, SPACER AND THRUST WASHER FOR ADJUSTMENTPart name Thickness mm Identification symbol Part No.

Thrust washer 1.8 18 MD754509(For adjustment of input shaft end play) 2.0 20 MD754508

2.2 22 MD7545072.4 24 MD753793

2.6 26 MD7537942.8 28 MD753795

Spacer 0.71 94 MR410594(For adjustment of output shaft end play) 0.74 95 MR410595

0.77 96 MR4105960.80 97 MR4105970.83 98 MR4105980.86 99 MR4105990.89 00 MR4106000.92 01 MR410601

0.95 02 MR4106020.98 03 MR4106031.01 04 MR4106041.04 05 MR4106051.07 06 MR4106061.10 07 MR4106071.13 08 MR4106081.16 09 MR4106091.19 10 MR4106101.22 11 MR410611

1.25 12 MR410612Spacer 1.10 J MD710454(For adjustment of differential case end play) 1.19 L MD710456

1.28 N MD7104581.37 P MD7104601.46 R MD7104621.55 T MD7104641.64 V MD7104661.73 X MD7104681.82 Z MD710470

Snap ring 1.6 None MD759666(For adjustment of forward clutch end play and 1.7 Blue MD759667

1.8 Brown MD7596681.9 None MD7521242.0 Blue MD7521252.1 Brown MD7521262.2 None MD7521272.3 Blue MD7521282.4 Brown MD7521292.5 None MD752130


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Part name Part No.Identification symbolThickness mm

Snap ring 2.6 Blue MD752131(For adjustment of forward clutch end play and 2.7 Brown MD752132

2.8 None MD7521332.9 Blue MD7521343.0 Brown MD754680

Spacer 0.75 0.82 MD722986(For adjustment of backlash between differential 0.83 0.92 MD722985

0.93 1.00 MD7229841.01 1.08 MD7229821.09 1.16 MD722983


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TORQUE SPECIFICATIONS

Item Nm

Oil guide mounting bolts 6 1

Reaction support mounting bolts 48 6

Oil pump mounting bolts 11 1

Bearing retainer mounting bolts 48 6

Oil pipe mounting bolts 11 1

Converter housing mounting bolts 48 6

Valve body mounting bolts 11 1

Valve body cover mounting bolts 11 1

Primary rear cover mounting bolts 23 3

Secondary rear cover mounting bolts 23 3

Inhibitor switch mounting bolts 11 1

Manual control lever mounting nut 22 3

Secondary pressure sensor mounting bolts 19 3

Primary pressure sensor mounting bolts 19 3

Primary speed sensor mounting bolts 11 1

Turbine speed sensor mounting bolts 11 1

Secondary speed sensor mounting bolts 11 1

Eyebolts 30 3

Oil cooler feed pipe mounting bolts 11 1Control cable bracket mounting bolts 23 3

Harness bracket mounting bolt (M6) 11 1

Harness bracket mounting bolt (M8) 23 3

Solenoid valve mounting bolts 6 1

Adjusting screw assembly mounting bolts 6 1

Outside valve body mounting bolts 11 1

Inside separating plate mounting bolts 6 1

Detent spring mounting bolt 6 1

Output shaft lock nut 190 20

Differential drive gear mounting bolts 135 5


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SEALANTS

Items Specified sealant

Primary rear cover Mitsubishi genuine sealant Part No. MD974421 or equivalent

Secondary rear coverorm- n-p ace gas et

Torque converter housing

Valve body cover

FORM-IN-PLACE GASKET (FIPG)The transmission has several areas where the form-in-place gasket (FIPG) is in use. To ensure thatthe gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket.Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks.Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowingof the fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessaryto apply the gasket evenly without a break, while observing the correct bead size.Since the FIPG used in the transmission hardens as it reacts with the moisture in the atmospheric air,it is normally used in the metallic flange areas.

DisassemblyThe parts assembled with the FIPG can be easily disassembled without use of a special method. Insome cases, however, the sealant between the joined surfaces may have to be broken by lightly strikingwith a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the

joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces.

Surface PreparationThoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraperor wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make surethat there are no oils, greases and foreign substances deposited on the application surfaces. Do notforget to remove the old FIPG remaining in the bolt holes.

FIPG ApplicationWhen assembling parts with the FIPG, you must observe some precautions, but the procedures is verysimple as in the case of a conventional precut gasket.Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle thebolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it ishardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. Whenthe parts are mounted, make sure that the gasket is applied to the required area only. In addition, donot apply any oil or water to the sealing locations and do not start the engine until a sufficient amountof time (about one hour) has passed after installation has been completed. The FIPG application proceduremay vary from area to area. Observe the procedure described in the text when applying the FIPG.


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CVT (E W) Special ToolsCVT (E W) Special Tools 23B-2-1

2. SPECIAL TOOLSTool Number Name Application

MB990930 Installer Adapter Installation of output shaft bearing outer race

MB990938 Handle Used together with the Installer Adapter

MD998334 Oil Seal Installer Installation of torque converter oil seal

MD998800 Oil Seal Installer Installation of drive shaft oil seal

MD998924 Spring CompressorRetainer

Removal and installation of snap ringsin forward clutch and reverse brakeEnd play adjustment of forward clutchand reverse brake

MD999590 Spring Compressor Removal and installation of snap ring inforward clutch

MB991628 Spring Compressor End play adjustment of forward clutch andreverse brake

MD999577 Spring Compressor Removal and installation of snap ring inreverse brake

MD998809 Lock Nut Wrench Removal and installation of lock nut on outputshaft


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CVT (E W) Special Tools23B-2-2

Tool ApplicationNameNumber

MD998801 Bearing Remover Removal of output shaft bearing anddifferential bearing

MD998812 Installer Cap Used together with Installer and InstallerAdapter

MD998817 Installer Adapter (34) Installation of output shaft bearing

MD998819 Installer Adapter (40) Installation of differential bearing


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CVT (E W) Transmission 23B-3-1

3. TRANSMISSIONDISASSEMBLY AND REASSEMBLYKEY POINTS FOR DISASSEMBLY AND REASSEMBLY

The valve body assembly underwent fluid pressure adjustments at the factory. Do not disturbsetting of the adjusting screw.The shift control solenoid valve must be installed into the original position whenever it has

been removed. Otherwise the factory-adjusted primary pressure characteristics will be affected.

10

11

5

1

8

9

20

622

23

21

16

15123

2

4

14

17

19

13

7

23 3 Nm

Apply automatictransmission fluid toall moving partsbefore installation.

23 3 Nm11 1 Nm

30 3 Nm

19 3 Nm

23 3 Nm22 3 Nm

11 1 Nm

11 1 Nm

11 1 Nm

11 1 Nm

11 1 Nm

11 1 Nm

19 3 Nm

11 1 Nm

18

Disassembly sequence1. Torque converter2. Control cable support bracket3. Harness bracket4. Harness bracket5. Harness bracket6. Oil level gauge7. Primary pressure sensor harness8. Eyebolt9. Oil cooler feed tube

10. Secondary speed sensor11. Turbine speed sensor12. Primary speed sensor

13. Primary pressure sensor14. Secondary pressure sensor15. Manual control lever16. Inhibitor switch17. Secondary rear cover18. Stopper19. Primary rear cover20. Valve body cover21. Solenoid valve harness connector

clamp22. Valve body assembly23. Steel ball


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CVT (E W) Transmission23B-3-2


11 1 Nm

48 6 Nm

48 6 Nm

48 6 Nm

6 1 Nm

11 1 Nm

2427

2829

35

43

53 54

55

56

51 49

475250

46

59

48

3839

3630

31

3725

3340 42

41

575834

60

44

26 32

48 6 Nm

45

Disassembly sequence24. Converter housing25. Spacer26. Accumulator spring27. Oil pipe28. Oil seal29. Oil seal30. Outer race31. Spacer32. Accumulator piston33. Oil filter34. Chain35. Oil pump drive sprocket36. Output shaft assembly

37. Differential assembly38. Bearing retainer39. Outer race40. Oil pump driven sprocket assembly41. Snap ring42. Oil pump assembly

43. Reaction support44. Thrust washer45. Pin46. Manual control lever shaft47. Parking roller rod48. Parking roller support shaft49. Parking roller support50. Parking sprag shaft51. Parking sprag52. Spring53. Forward clutch assembly54. Thrust bearing55. Planetary carrier

56. Reverse brake assembly57. Oil guide58. Oil pipe59. Oil seal60. Gear and case kit


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DISASSEMBLY

CautionThe automatic transmission includes manyhigh-precision components. All parts must be handledcarefully not to give damage to them when thetransmission is disassembled and reassembled.Place a rubber mat over the bench on which

disassembly work is going to be performed. Alwayskeep the mat surface clean.Do not use cotton gloves and shop towel or rag whendisassembling the transmission. Use nylon cloth orpaper towel if necessary.All removed parts must be washed. Metal parts maybe washed in solvent but must be dried usingcompressed air after washing.Wash the clutch discs, brake discs, plastic thrustplates and rubber parts in automatic transmissionfluid (ATF). Keep the washed parts away from dust.Whenever transmission parts are found damaged, theoil cooler system components must be disassembledand washed.

(1) Remove the torque converter from the transmission.

(2) Remove the control cable support bracket and harnessbracket from the transmission case.


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(3) Remove the harness brackets at two places on thetransmission case.

(4) Remove the oil level gauge from the valve body cover.

(5) Unclamp and detach the primary pressure sensor harnessconnector from the oil cooler feed tube.

(6) Unclamp and detach the primary pressure sensor harnessfrom the valve body cover, disconnect the harnessconnector from the primary pressure sensor, then removethe primary pressure sensor harness.

(7) Remove the two eyebolts, four gaskets, and oil coolerfeed tube from the transmission case.


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(8) Remove the secondary speed sensor from the converterhousing.

(9) Remove the turbine speed sensor from the transmissioncase.

(10)Remove the primary speed sensor from the transmissioncase.

(11)Remove the primary pressure sensor from the primaryrear cover.

(12)Remove the secondary pressure sensor from thesecondary rear cover.


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(13)Remove the manual control lever from the manual controlshaft.

(14)Remove the inhibitor switch from the transmission case.

(15)Remove the secondary rear cover from the transmissioncase.

(16)Remove the O-ring and stopper from the transmissioncase.

(17)Remove the primary rear cover from the transmissioncase.


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(18)Remove the three O-rings from the transmission case.

(19)Remove the valve body cover from the transmission case.

(20)Remove the clamp that holds the connector of solenoidvalve harness.

(21)Remove 34 bolts shown in the illustration, then removethe valve body assembly from the transmission case.NOTEDo not remove the two bolts shown in the illustration.

(22)Remove from the valve body the steel ball indicated inthe illustration.


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(23)Remove the converter housing from the transmissioncase.CautionThe spacer (for adjusting the differential bearingclearance), five O-rings, and two accumulator springsmay come off together with the converter housing.

(24)Remove the five O-rings and the spacer for adjustingthe differential bearing clearance (see the illustration).NOTEThe O-ring and spacer may attach to the converter housingwhich was removed in the preceding step.

(25)Remove the two accumulator springs from the reactionshaft support.

(26)Remove the oil pipe from the converter housing.

(27)Remove the accumulator piston from the reaction shaftsupport.


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(28)Remove the oil filter from the transmission case.

(29)Remove the chain and oil pump drive sprocket.

(30)Remove the output shaft assembly and differentialassembly from the transmission case.

(31)Remove the bearing retainer and outer race.

(32)Remove the oil pump driven sprocket from the oil pumpby opening the snap ring shown in the illustration.


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(33)Detach from the oil pump the snap ring that retains theoil pump driven sprocket.

(34)Remove the four bolts shown in the illustration, thenremove the oil pump assembly from the transmissioncase.

(35)Remove the O-ring shown in the illustration from thetransmission case.

(36)Remove the reaction shaft support from the transmissioncase.

(37)Remove the thrust washer from the forward clutch.NOTEThe thrust washer may attach to the reaction shaft supportwhich was removed in the preceding step.


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(38)Remove the knock pin that is positioning the manualcontrol shaft.

(39)Remove the manual control shaft and parking roller rodfrom the transmission case.

(40)Remove the two parking roller support shafts from thetransmission case.

(41)Remove the parking roller support from the transmissioncase.

(42)Remove the parking sprag shaft, then remove the parkingsprag and spring from the transmission case.


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(43)Remove the forward clutch assembly and input shaft outof the transmission case.

(44)Remove the planetary carrier assembly out of thetransmission case.

(45)Remove the reverse brake assembly out of thetransmission case.

(46)Remove the oil guide from the transmission case.

(47)Remove the oil pipes out of the transmission case.


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ASSEMBLY

CautionDo not reuse any of the removed O-rings and oil seals.Be sure to use new O-rings and oil seals when thetransmission is reassembled.Only blue petrolatum jelly and white Vaseline maybe used during assembly.

The friction elements and the parts having surfaceson which other parts rotate or slide must be coatedwith ATF before they are assembled. New brake andclutch discs must be immersed in ATF for more than2 hours before installation.Do not apply sealant and adhesive to any preformedgaskets.If a bushing is excessively worn or otherwisedamaged, replace the assembly of which the bushingforms part.Do not use cotton gloves and shop towel or rag duringassembly work. Use nylon cloth gloves and papertowel if necessary.Do not forget to change the fluid in the oil cooler.

(1) Install a new oil seal in the transmission case using thespecial tool.

(2) Install the oil pipes in the transmission case.

MD998800


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(3) Install the oil guide on the transmission case.

(4) Turn the flats of the reverse brake bearing to the positionsindicated in the illustration.

(5) Install the reverse brake assembly in the transmissioncase while aligning the oil pipe and knock pin positions.

(6) Install the thrust bearing in the planetary carrier.

(7) Install the planetary carrier assembly in the transmissioncase.


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(8) Install the input shaft and forward clutch assembly inposition in the transmission case.

(9) Install the parking sprag and spring in position in thetransmission case, then install the parking sprag shaft.

(10)Install the parking roller support on the transmission case.

(11)Install the two parking roller support shafts in thetransmission case.

(12)Install the manual control shaft and parking roller rodon the transmission case.


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(13)Push the manual control shaft in the direction indicatedin the illustration, then fit a new O-ring in the O-ring groove.

(14)Install the knock pin for positioning the manual controlshaft in the transmission case.

(15)Measure the dimensions A and B and obtain the differencebetween them (A B). Select an appropriate thrust washeraccording to the table below such that the end play iswithin the standard value range.Standard value: 0.3 0.6 mm

Difference betweenmeasurements (A B) mm

Part No. (thickness mm)

2.15 2.35 MD754509 (1.8)

2.35 2.55 MD754508 (2.0)

2.55 2.75 MD754507 (2.2)

2.75 2.95 MD753793 (2.4)

2.95 3.15 MD753794 (2.6)

3.15 3.35 MD753795 (2.8)

(16)Install the selected thrust washer on the forward clutch.

A

B


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(17)Install new seal rings on the reaction shaft support.

(18)Install the reaction shaft support in position in thetransmission case.

(19)Make sure the end play of the input shaft is within thestandard value range.

Standard value: 0.3 0.6 mm

(20)Install a new O-ring in the shown position in thetransmission case.

(21)Install the oil pump assembly in the transmission case.

Input shaft


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(22)Retain the oil pump driven sprocket with the snap ringas shown.

(23)Install the oil pump driven sprocket while opening thesnap ring.

(24)Install the bearing retainer in the shown position in thetransmission case, then install the bearing outer raceusing the indicated special tools.

(25)Install the output shaft assembly and differential assemblyin the transmission case, as shown.

(26)Install two new seal rings on the oil pump drive sprocket.

MB990938MB990930


Seal rings

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(27)Install the chain and oil pump drive sprocket.

(28)Fit a new O-ring on the oil filter.

(29)Install the oil filter in the shown position in the transmissioncase.

(30)Fit a new seal ring on the accumulator piston, then installthe piston on the reaction shaft support.

(31)Install the two accumulator springs on the reaction shaftsupport.

O-ring


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(32)Place two pieces of solder (each approx. 10 mm in lengthand 2 mm in diameter) in the shown locations of thedifferential ball bearing.

(33)Place two pieces of solder (each approx. 10 mm in lengthand 2 mm in diameter) in the shown locations of theoutput shaft hole in the converter housing.

(34)Install the bearing outer race in the converter housingusing the indicated special tools.

(35)Install the converter housing on the transmission case.(36)Remove the converter housing from the transmission case

and take out the solder pieces (to be used in obtainingthe differential bearing end play).

(37)Remove the bearing outer race from the converter housingand take out the solder pieces (to be used in obtainingthe output shaft bearing preload).

(38)Measure using a micrometer the thickness of the crushedsolder pieces. Based on the results, select spacers whichadjust the end play and preload to the following standardvalues, respectively, according to the tables below.Standard value for differential bearing end play:

0.045 0.165 mmStandard value for output shaft bearing preload:

0.045 0.105 mm

Solder

Solder

MB990938

MB990930


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Differential bearing spacer

Solder thickness mm Part No. (thickness mm)

1.16 1.25 MD710454 (1.10)

1.25 1.34 MD710456 (1.19)

1.34 1.43 MD710458 (1.28)

1.43 1.52 MD710460 (1.37)

1.52 1.61 MD710462 (1.46)

1.61 1.70 MD710464 (1.55)

1.70 1.79 MD710466 (1.64)

1.79 1.88 MD710468 (1.73)

1.88 1.97 MD710470 (1.82)

Output shaft bearing spacer

Solder thickness mm Part No. (thickness mm)

0.62 0.65 MR410594 (0.71)

0.65 0.68 MR410595 (0.74)

0.68 0.71 MR410596 (0.77)

0.71 0.74 MR410597 (0.80)

0.74 0.77 MR410598 (0.83)

0.77 0.80 MR410599 (0.86)

0.80 0.83 MR410600 (0.89)

0.83 0.86 MR410601 (0.92)

0.86 0.89 MR410602 (0.95)

0.89 0.92 MR410603 (0.98)

0.92 0.95 MR410604 (1.01)

0.95 0.98 MR410605 (1.04)

0.98 1.01 MR410606 (1.07)

1.01 1.04 MR410607 (1.10)

1.04 1.07 MR410608 (1.13)

1.07 1.10 MR410609 (1.16)

1.10 1.13 MR410610 (1.19)

1.13 1.16 MR410611 (1.22)

1.16 1.19 MR410612 (1.25)

(39)Install the selected output shaft bearing spacer in theconverter housing as shown.


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(40)Use the indicated special tools to install the bearing outerrace in the converter housing.

(41)Use the indicated special tool to install a new oil sealin the converter housing.

(42)Use the indicated special tool to install a new oil sealin the converter housing.

(43)Install the oil pipe on the converter housing.

(44)Install the differential bearing spacer selected in step 38on the differential bearing, then install new O-rings inthe five places in the transmission case as shown inthe illustration.

MB990938

MB990930

MD998334

MD998800


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(45)Apply a 1.6 mm diameter bead of liquid gasket to theconverter housing flange, beginning with a point in zoneA shown in the illustration.

Specified sealant:Mitsubishi genuine sealant Part No. MD974421or equivalent

(46)Install the converter housing in the transmission case.

(47)Fit a new O-ring on the solenoid valve harness connector.

(48)Install the steel ball in the indicated position of the valvebody.

(49)Install the solenoid valve harness connector on thetransmission case as shown in the illustration and attachthe clamp to the connector.

A

O-ring


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(50)Insert the pin of the manual valve in the groove formedin the detent plate of the manual control lever shaft.

(51)Install the valve body assembly on the transmission case,then secure it with 34 bolts as shown in the illustration.

CautionThe inside separating plate has to be replaced witha new one before the valve body assembly is installed.Replacement of the plate involves disassembly ofthe valve body assembly. (Refer to 6. Valve Body Disassembly and Reassembly.)

(52)Apply a 2.5 mm diameter bead of liquid gasket to thevalve body cover flange, beginning with a point in zoneA shown in the illustration.Specified sealant:

Mitsubishi genuine sealant Part No. MD974421or equivalent

(53)Install the valve body cover on the transmission case.

(54)Install the new O-rings in the three places on thetransmission case as shown in the illustration.

(55)Apply a 1.6 mm diameter bead of liquid gasket to theprimary rear cover mounting surface of the transmissioncase, beginning with a point in zone A shown in theillustration.Specified sealant:


A

A


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(56)Install the primary rear cover on the transmission case.CautionReplace the seal bolt shown with a new one.

(57)Install a stopper and a new O-ring in the shown placeon the transmission case.

(58)Apply a 1.6 mm diameter bead of liquid gasket to thesecondary rear cover mounting surface of the transmissioncase, starting with a point within zone A shown in theillustration.Specified sealant:


(59)Install the secondary rear cover on the transmission case.

(60)Install the inhibitor switch on the transmission case.

A


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(61)Install the manual control lever on the manual controlshaft.

(62)Install the secondary pressure sensor fitted with a newO-ring on the secondary rear cover.

(63)Install the primary pressure sensor fitted with a new O-ringon the primary rear cover.

(64)Install the primary speed sensor fitted with a new O-ringon the transmission case.

(65)Install the turbine speed sensor fitted with a new O-ringon the transmission case.


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(66)Install the secondary speed sensor fitted with a new O-ringon the converter housing.

(67)Install a new gasket, the eyebolt and the oil cooler feedtube on the transmission case as shown in the illustration.

(68)To the primary pressure sensor connect the connectorof its harness and secure the connector with the clampon the valve body cover.

(69)Secure the connector of the primary pressure sensorharness with the clamp on the oil cooler feed tube.

(70)Install the oil level gauge on the valve body cover.


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(71)Install the two harness brackets on the transmission case.

(72)Install the control cable support bracket and harnessbracket on the transmission case.

(73)Install the torque converter on the transmission whilealigning the flats on the torque converter with those inthe oil pump drive sprocket.

(74)Measure dimension A indicated in the illustration. Themeasurement should be equal to the reference valueshown below. If necessary push the torque converterinto the transmission completely.Reference value: 12.2 mm

Flats on torque converter

Flat in oil pumpdrive sprocket


A

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CVT (E W) Forward Clutch and Input Shaft 23B-4-1

4. FORWARD CLUTCH AND INPUT SHAFTDISASSEMBLY AND REASSEMBLY


13

14

11 12

109 8

3

1

2

4

5

6

7

Model Clutch disc Clutch plate Clutch reaction plate

F1C1A-1 2 2 1

F1C1A-2 3 3 1

Disassembly steps1. Input shaft2. Seal ring

E 3. BearingD 4. Snap ringC 5. Clutch reaction plateC 6. Clutch discC 7. Clutch plate

A B 8. Snap ring9. Spring retainer

10. Return spring11. Clutch piston

A 12. D-ring13. Clutch retainer

A 14. D-ring


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CVT (E W) Forward Clutch and Input Shaft23B-4-2

DISASSEMBLY SERVICE POINTA SNAP RING REMOVAL

To remove the snap ring, compress the return spring by holdingdown the spring retainer using the indicated special tools.

REASSEMBLY SERVICE POINTSA D-RING INSTALLATION

Coat new D-rings with ATF, blue petrolatum or white Vaseline,then fit them into the illustrated locations, taking care notto give damage to them.

B SNAP RING INSTALLATION(1) Coat the lip seal of the spring retainer with blue petrolatum.(2) To install the snap ring, compress the return spring by

holding down the spring retainer using the indicatedspecial tools.

C CLUTCH PLATES / CLUTCH DISCS / CLUTCHREACTION PLATE INSTALLATION

Install the clutch plates, clutch discs, and reaction plate,directing their ends as shown in the illustration.CautionImmerse the clutch discs in ATF before assembling themwith the other parts.

MD998924

MD999590

D-ring


MD998924

MD999590

Clutch plate

Clutch reaction plate

Clutch disc

Roundedge

Stamped mark side

Clutch plate

Clutch reaction plate

Clutch disc

Roundedge

Stamped mark side

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CVT (E W) Forward Clutch and Input Shaft 23B-4-3

D SNAP RING INSTALLATION(1) Fit the snap ring in the groove formed in the forward

clutch retainer.(2) Press all around the clutch reaction plate using the

indicated special tools.(3) Check whether the clearance between the snap ring and

clutch reaction plate conforms to the standard valueindicated below.

(4) If the clearance deviates from the standard value, adjustit by changing the snap ring to a one of an appropriatesize.


E BEARING INSTALLATIONPress fit the bearing until its stamped mark surface becomesflush with the surface A shown.

MD998924

MB991628


Stamped markside

A

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CVT (E W) Reverse Brake 23B-5-1

5. REVERSE BRAKEDISASSEMBLY AND REASSEMBLY


12

3

67

89

10

5

4

Model Brake disc Brake plate Brake pressure plate Brake reaction plate

3-brake-disc type 3 2 1 1

4-brake-disc type 4 3 1 1

Disassembly stepsD 1. Snap ringC 2. Brake reaction plateC 3. Brake discC 4. Brake plate

5. Brake pressure plate

A B 6. Snap ring7. Spring retainer8. Return springA 9. Brake piston

10. Brake retainer


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CVT (E W) Reverse Brake23B-5-2

DISASSEMBLY SERVICE POINTA SNAP RING REMOVAL

To remove the snap ring, compress the return spring by holdingdown the spring retainer using the indicated special tools.

REASSEMBLY SERVICE POINTSA BRAKE PISTON INSTALLATION

Apply blue petrolatum to the indicated portions of the brakepiston in order to prevent it from being damaged duringinstallation.

B SNAP RING INSTALLATION(1) Compress the return spring by holding down the spring

retainer using the indicated special tools.

(2) Install the snap ring with its ends directed as shown inthe illustration.CautionNever locate the ends at the positions A shown.

C BRAKE PLATES / BRAKE DISCS / BRAKEREACTION PLATE / BRAKE PRESSURE PLATEINSTALLATION

Install the brake plates, brake discs, brake reaction plateand brake pressure plate, directing their ends as shown inthe illustration.CautionImmerse the brake discs in ATF before assembling themwith the other parts.

MD998924

MD999577

MD998924

MD999577

Opening

A

A

Brake disc

Brake pressure plateBrakeplate

Round edge

Brake reactionplate

Stamped mark side

AK102806


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CVT (E W) Reverse Brake 23B-5-3

D SNAP RING INSTALLATION(1) Fit the snap ring in the groove formed in the reverse

brake retainer.(2) Press all around the brake reaction plate using the

indicated special tools.(3) Check whether the clearance between the snap ring and

brake reaction plate conforms to the standard value.(4) If the clearance deviates from the standard value, adjust

it by changing the snap ring to a one of an appropriatesize.


Brake disc

Brake pressure plateBrake plate

Round edge

Brake reaction plateStamped markside

AK102840

MD998924MB991628

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CVT (E W) Valve Body 23B-6-1

6. VALVE BODYDISASSEMBLY AND REASSEMBLYKEY POINTS FOR DISASSEMBLY AND REASSEMBLY

The valve body assembly underwent fluid pressure adjustments at the factory. Do not disturbsetting of the adjusting screw.The shift control solenoid valve must be installed into the original position whenever it has

been removed. Otherwise the factory-adjusted primary pressure characteristics will be affected.


1

7 89

10

1615

14131211

17 1819

20

2423

2221

47 484956 50

51

5453

52

6

4544

46

43

55

58

3534

3637

3332

31

2930

2625

2728

2

4

385

40

41

4239

3

57

59

11 1 Nm

6 1 Nm

6 1 Nm

6 1 Nm

6 1 Nm

6 1 Nm


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CVT (E W) Valve Body23B-6-2

Disassembly steps1. Manual valve2. Detent spring3. Inside separating plate

E 4. Oil strainer5. Oil strainer

A D 6. Solenoid valve harness7. Stopper plate8. Stopper plug

9. Damper clutch control valve10. Damper clutch control valve spring11. Stopper plate12. Stopper plug13. Line pressure relief valve spring14. Line pressure relief valve15. Stopper plate16. Line pressure relief sleeve17. Stopper plate18. Regulator valve sleeve19. Regulator valve spring20. Regulator valve21. Stopper plate22. Stopper plug23. Torque converter pressure valve

spring24. Torque converter pressure valve25. Stopper plate26. Stopper plug27. Clutch pressure control valve

spring28. Clutch pressure control valve29. Stopper plate30. Stopper plug31. Needle roller

32. Clutch pressure reducing valvespring

33. Clutch pressure reducing valve34. Stopper plate35. Stopper plug36. Primary pressure relief valve spring37. Primary pressure relief valve38. Inside valve body

39. Outside separating plateC 40. Steel ballC 41. One-way valve springC 42. Oil strainer

43. Stopper plate44. Stopper plug45. Exhaust valve spring46. Exhaust relief valve

B B 47. Adjusting screw assembly48. Plug49. Shift control valve spring50. Shift control valve51. Shift control valve spring52. Plug53. Reducing valve spring

54. Reducing valveC A 55. Line pressure control solenoidvalve

C A 56. Shift control solenoid valveC A 57. Dumper clutch control solenoid

valveC A 58. Clutch pressure control solenoid

valve59. Outside valve body


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CVT (E W) Valve Body 23B-6-3

DISASSEMBLY SERVICE POINTSA SOLENOID VALVE HARNESS REMOVAL

(1) Remove the oil temperature sensor from the valve bodyby pressing the claws indicated in the illustration.

(2) Remove all the solenoid valve harness by disconnectingtheir connectors from the solenoid valves.

B ADJUSTING SCREW ASSEMBLY REMOVALRemove the adjusting screw assembly.CautionNever turn the adjusting screws indicated in theillustration. If either or both of them are accidentallyturned, replace the whole valve body assembly.

C SOLENOID VALVE REMOVALBefore removing the solenoid valves, put marks on themand the valve body to help identify their locations duringreinstallation.CautionThe shift control solenoid valve can not be replacedindividually. If it requires replacement, replace the valvebody assembly.

REASSEMBLY SERVICE POINTSA SOLENOID VALVE INSTALLATION

Set new O-rings on solenoid valves. Install the solenoid valvesinto correct locations in accordance with the marks madeat the time of removal.CautionThe shift control solenoid valve cannot be replacedindividually. If it requires replacement, replace the valvebody assembly.

B ADJUSTING SCREW ASSEMBLY INSTALLATIONInstall the adjusting screw assembly in portion.CautionNever turn the adjusting screws indicated in theillustration. If either or both of them are accidentallyturned, replace the whole valve body assembly.

Adjusting screw

Shift control solenoid valve


Shift control solenoid valve

Adjusting screw

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CVT (E W) Valve Body23B-6-4

C OIL STRAINER / ONE-WAY VALVE SPRING /STEEL BALL INSTALLATION

Install the oil strainer, one-way valve springs and steel ballsinto the indicated locations.

D SOLENOID VALVE HARNESS INSTALLATION(1) Fit the claws of the oil temperature sensor indicated in

the illustration snugly in the valve body.

(2) Connect the solenoid valve harness connectors to thecorresponding solenoid valves correctly.

Location Solenoid valve Wire colorcode

Connectorhousing color

1 Clutch pressurecontrol solenoid valve

Yellow, red,red

Milky white

2 Line pressure controlsolenoid valve

Orange,yellow, yellow

Black

3 Dumper clutchcontrol solenoid valve

Green, yellow Milky white

4 Shift control solenoidvalve

Blue, red Black

E OIL STRAINER INSTALLATIONInstall the oil strainer into the indicated location.

Oil strainer

One-way valve springand steel ball

1

2

3

4


Oil strainer

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CVT (E W) Output Shaft 23B-7-1

7. OUTPUT SHAFTDISASSEMBLY AND REASSEMBLY


1

23

5

4

Disassembly stepsA C 1. Lock nutB B 2. Taper roller bearing

3. Transfer driven gear

C A 4. Taper roller bearing5. Output shaft

DISASSEMBLY SERVICE POINTSA LOCK NUT REMOVAL

(1) Undo staking of the lock nut.

(2) Remove the lock nut using the indicated special tool.


MD998809

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CVT (E W) Output Shaft23B-7-2

B TAPER ROLLER BEARING REMOVALUse the indicated special tool to remove the taper rollerbearing.

C TAPER ROLLER BEARING REMOVALUse the indicated special tool to remove the taper rollerbearing.

REASSEMBLY SERVICE POINTSA TAPER ROLLER BEARING INSTALLATION

Use the indicated special tools to install the taper roller bearing.

B TAPER ROLLER BEARING INSTALLATIONUse the indicated special tools to install the taper roller bearing.

C LOCK NUT INSTALLATION(1) Apply ATF to the thread portion of the lock nut before

installation.(2) Use the indicated special tool to tighten the lock nut to

the specified torque.(3) Loosen the lock nut one complete turn, then tighten it

again to the specified torque.

MD998801

MD998801

MD998812MD998817

MD998801

MD998801

MD998812MD998817


MD998809

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CVT (E W) Output Shaft 23B-7-3

4. Stake the lock nut securely into the notch in the outputshaft.


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CVT (E W) Differential 23B-8-1

8. DIFFERENTIALDISASSEMBLY AND REASSEMBLY


7

6

5

3

10

97

6

8

9

1

24

135 5 Nm

Disassembly stepsE 1. Differential drive gear

A D 2. Ball bearingB C 3. Ball bearing

B 4. Lock pinA 5. Pinion shaft

A 6. PinionA 7. WashersA 8. Side gearsA 9. Spacers

10. Differential case

DISASSEMBLY SERVICE POINTSA BALL BEARING REMOVAL

Use the indicated special tool to remove the ball bearingfrom the differential case.


MD998801

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CVT (E W) Differential23B-8-2

B BALL BEARING REMOVALUse the indicated special tool to remove the ball bearingfrom the differential case.

REASSEMBLY SERVICE POINTSA SPACER / SIDE GEAR / WASHER / PINION /

PINION SHAFT INSTALLATION(1) Fit the spacer on the back side of each side gear.(2) Install the side gears fitted with the spacers into the

differential case.NOTEUse spacers of a thickness of 0.93 1.00 mm wheninstalling new side gears.

(3) Fit the washer on the back side of each pinion. Meshboth the pinions simultaneously with the side gears, thenbring the pinions into position inside the differential casewhile rotating them.

(4) Insert the pinion shaft into the differential case whilealigning the lock pin holes.

(5) Measure the backlash between each side gear and thepinions.

(6) If the backlash deviates from the standard value, replacethe spacer of the side gear with a one of an appropriatethickness and measure the backlash again forconfirmation.NOTEThe backlash on one side gear should be equal to thaton the other after adjustments.

B LOCK PIN INSTALLATIONInsert the lock pins into the differential case using a presswith a force larger than 5 kN until their top ends are lowerthan the differential drive gear mounting surface.

MD998801

Lock pin

Differential drive gearmounting surface


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CVT (E W) Differential 23B-8-3

C BALL BEARING INSTALLATIONUse the indicated special tools to install the ball bearing onthe differential case.

D BALL BEARING INSTALLATIONUse the indicated special tools to install the ball bearing onthe differential case.

E DIFFERENTIAL DRIVE GEAR INSTALLATION(1) Place the differential drive gear in position on the

differential case.(2) Apply ATF to each of the bolt and tighten the bolts in

the numbered sequence to the specified torque.

MD998812

MD998819

MD998812

MD998819

1

2

3

45

6

7

8

cvt_mmc

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